Will the Image Sensor Solve This Problem?

Image sensors are a great choice for users looking to perform a visual inspection for the first time.

For many people, complex image processing systems can be absolutely overwhelming. However, visual inspection systems are an indispensable tool for automatic quality control. Multiple controls or multi-sensor controls that previously required costly, complex image processing systems can now be completed with an economical yet capable image sensor.

Image sensors are an excellent choice for relatively simple applications, and many users are looking for a solution that is easy to implement.

What is an Image Sensor and what are its benefits?

Image sensors are self-contained devices that include image illumination, lens and camera in a single compact unit, simplifying application.

The following are the top 3 benefits of image sensors identified by users as reasons for their choice:

1. Save time and money.
Image sensors are generally smaller, lower cost and less complex than smart cameras, making image sensors one of the easiest automated vision inspection solutions. Having built-in lighting makes it even easier to set up a basic image control system without requiring any additional devices. Even a user who has not had a similar experience before can achieve results within minutes.

2. Use a single device for multiple checkpoints.
Because image sensors capture an entire image rather than a single point, they can perform many checks simultaneously that would be done with many photoelectric sensors.

3. Verify shapes, patterns, colors and more.
Image sensors can be black-and-white or color. Monochrome image sensors are often used in situations where colors are not required to confirm the presence or shape of objects or to distinguish between OK/NG states. In addition, color image sensors see in true color and can be used successfully in applications that require color control and color separation.

As a result, thanks to both their cost and easy-to-use features, image sensors offer a very important solution for users in automatic quality control and visual control applications. In addition to all these, it can meet many different applications due to its flexible programmable structure. Thanks to its autofocus feature, it provides you with flexibility to meet changing application requirements with different working distances, interchangeable lenses and alternative attachable lighting adapters.

Ideal Applications for Image Sensors — And When to Switch to a Smart Camera?

Image sensors are best for simple quality control applications such as presence/absence, similarity, label checking, verifying the color of a product, etc. A similarity ratio check is a great practice for someone using an image sensor for the first time because it simply requires capturing the image of a correct condition. When the sensor detects a faulty part, it sends an error output to the sensor line and the product is rejected.

For example, an image sensor can be used to verify the presence of a label on a product. Another good practice is complete assembly verification. For example, an image sensor can be used to verify that all the correct components are present in a completed fuse box assembly.

The next step up from an image sensor will be a smart camera, which typically requires a PC for programming but provides additional features such as feature measurement and error analysis. Smart cameras are ideal if you need more functionality than an image sensor, but you still need a versatile and easy-to-use solution. At this point it's important to find a camera with intuitive software that can handle complex controls while still being user-friendly.

Finally, by collaborating with a partner that offers both image sensor and smart camera solutions, you can make this decision more easily together when necessary.